894 CHAPTER 13.

ANALOG ELECTRONIC INSTRUMENTATION

13.7.6 Using loop calibrators

Special-purpose electronic test instruments called loop calibrators exist for the express purpose of
4-20 mA current loop circuit troubleshooting. These versatile instruments are generally capable
of not only measuring current, but also sourcing current to unpowered devices in a loop, and also
simulating loop-powered 4-20 mA transmitters.
A very popular loop calibrator unit is the Altek model 334A, a battery-powered, hand-held unit
with a rotary knob for current adjustment and toggle switches for mode setting. The following
illustration shows how this calibrator would be used to measure current in a functioning input signal
loop8 :

Controller

PV

SP
Out
2-wire, loop-powered
pressure transmitter A
/M

24 VDC
+V
2-wire cable
Voltage-sensing
250 Ω PV input analog-to-digital
converter

Applied pressure =
392.3 inches W.C.
mA
READ

mA OFF
READ VDC % 4 to 20 mA

LOOP CALIBRATOR
Loop calibrator
POWER 2-WIRE
TRANSMITTERS
100% acting as an
Toggle switch SOURCE 20 mA

READ ADJUST
electrical load
set to "READ" 2-WIRE 4 mA
TRANSMITTER
0%
SIMULATOR

Here, the loop wiring is broken at the negative terminal of the loop-powered transmitter, and
the calibrator connected in series to measure current. If this loop had a test diode installed, the
calibrator could be connected in parallel with the diode to achieve the same function. Note the
polarity of the calibrator’s test leads in relation to the circuit being tested: the calibrator is acting
8 In the following illustrated examples, the transmitter is assumed to be a pressure transmitter with a calibrated

range of 0 to 750 inches of water column, 4-20 mA. The controller’s PV (process variable) display is appropriately
ranged to display 0 to 750 as well.
13.7. TROUBLESHOOTING CURRENT LOOPS 895

as a passive device (i.e. as a load rather than as a source), with the more positive loop terminal
connected to the calibrator’s red test lead and the more negative terminal connected to the black
test lead.

The same loop calibrator may be used to source (or drive) a 4-20 mA signal into an indicating
instrument to test the function of that instrument independently. Here, we see the Altek calibrator
used as a current source to send a 16.00 mA signal to the PV (process variable) input of the controller,
in order to check that the controller properly senses and displays the analog current signal:

Controller

PV

SP
Out
mA
READ

A
mA
READ VDC
OFF
% 4 to 20 mA /M
LOOP CALIBRATOR
POWER 2-WIRE
TRANSMITTERS
100%
24 VDC
Toggle switch SOURCE 20 mA

+V
READ ADJUST

set to "SOURCE" 2-WIRE 4 mA

TRANSMITTER
0%
SIMULATOR

Voltage-sensing
250 Ω PV input analog-to-digital
Loop calibrator converter
acting as an
electrical source

No transmitter need be included in this illustration, because the calibrator takes its place. Note
how the calibrator functions here as an active source of current rather than a passive load as it
was in the last example. Not only does it supply the information (i.e. regulate the current), but it
also provides the energy in the circuit. The DC power source inside the controller is not used for
loop power, because the calibrator in “source” mode provides the necessary power to drive current
through the 250 ohm resistor.
896 CHAPTER 13. ANALOG ELECTRONIC INSTRUMENTATION

A very common use of a loop calibrator in “source” mode is to test a control valve for proper
calibration, quick response, and to measure friction. Here, the loop calibrator takes place of the loop
controller output, serving as the sole source of current to the I/P transducer:

mA
READ
Air supply
mA OFF
READ VDC % 4 to 20 mA

tube
LOOP CALIBRATOR
POWER 2-WIRE
TRANSMITTERS
100%

Toggle switch SOURCE 20 mA

I
/P
READ ADJUST

set to "SOURCE" 2-WIRE 4 mA

TRANSMITTER
0%
SIMULATOR

tube

Loop calibrator
acting as an
electrical source
Current-to-Pressure (I/P)
signal transducer
Control valve
(50% open)

This circuit configuration is extremely useful to any instrument technician testing the response
of a control valve, because it allows the signal to be finely adjusted while in the direct presence of
the valve to monitor its motion. If a control valve is suspected of having excessive friction in its
moving parts, for instance, a technician may test the valve by incrementing and decrementing the
loop calibrator’s source current in progressively smaller steps. Large step-changes in current should
cause the valve to overcome friction and move, but small step-changes will fail to move the valve
mechanism when frictional forces exceed the incremental forces produced by the changing pressure.
13.7. TROUBLESHOOTING CURRENT LOOPS 897

A photograph showing this very use of a loop calibrator in a valve rebuild shop appears here:

In this particular example, the loop calibrator connects to a device on the control valve called a
positioner, which is a more sophisticated device than an I/P transducer. In addition to converting a
4-20 mA signal into an air pressure, the positioner also actively monitors the valve stem’s position to
ensure it goes to the correct position for any given 4-20 mA command signal. Here, the technician
is using the loop calibrator to verify the control valve faithfully obeys the command signal through
the entire 4 to 20 milliamp signal range.
898 CHAPTER 13. ANALOG ELECTRONIC INSTRUMENTATION

An alternative method of sourcing a known current signal into an indicating instrument providing
loop power is to set the loop calibrator to a mode where it mimics (or simulates) the electrical
behavior of a loop-powered (2-wire) transmitter. In this mode, the calibrator serves to regulate
loop current at a user-determined value, but it provides no motivating voltage to drive this current.
Instead, it passively relies on the loop’s regular voltage source to provide the necessary electromotive
force:

Controller

PV

SP
2-wire, loop-powered Out
pressure transmitter
(disconnected from loop) A
/M

24 VDC
+V
2-wire cable
Voltage-sensing
250 Ω PV input analog-to-digital
converter

mA
READ

mA OFF
READ VDC % 4 to 20 mA

LOOP CALIBRATOR
Loop calibrator
POWER 2-WIRE
TRANSMITTERS
100% acting as an
Toggle switch
SOURCE 20 mA

READ ADJUST
electrical load
set to "2-WIRE 2-WIRE 4 mA
0%

SIMULATE"
TRANSMITTER
SIMULATOR

Note the polarity of the calibrator’s test leads in relation to the controller: the red test lead
connects to the positive loop power terminal while the black lead connects to the positive input
terminal. Here, the calibrator acts as an electrical load, just as a loop-powered transmitter acts as
an electrical load. Like a 2-wire transmitter, the calibrator in simulate mode regulates the circuit
current while depending on an external voltage source for energy.
This simulate transmitter mode is especially useful for testing a 4-20 mA loop at the end of
the cable where the transmitter is physically located. After disconnecting the cable wires from the
transmitter and re-connecting them to the loop calibrator (set to “simulate” mode), the calibrator
may be used to simulate a transmitter measuring any value within its calibrated range.
13.7. TROUBLESHOOTING CURRENT LOOPS 899

A legacy loop calibrator still familiar to many instrument technicians at the time of this writing
is the classic Transmation model 1040:

Other examples of vintage loop calibrator technology include the Nassau model 8060 (left) and
the Biddle Versa-Cal (right):
900 CHAPTER 13. ANALOG ELECTRONIC INSTRUMENTATION

A modern loop calibrator manufactured by Fluke is the model 705:

With this calibrator, the measure, source, and simulate modes are accessed by repeatedly pushing
a button, with the current mode displayed on the screen:

Note the dual-numeric display, showing both loop current and percentage (assuming a 4-20 mA
range).